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Date:         Tue, 25 Jul 2000 15:55:17 -0400
Reply-To:     ehall@together.net
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Ezra Hall <ehall@together.net>
Subject:      Re: Valve Cover Gaskets and Lifter
Comments: To: Donna Cassano <pokeswagon@blazenet.net>
Content-Type: text/plain; charset="iso-8859-1"

Donna and folks on the list, We just returned from a 5K mile 3 week trip in our '88 westy, during which we had a slight problem with one of the hydraulic lifters. Before I describe the problem and my temporary solution, let me share what I did prior to the trip with regards to the lifters and valve covers. On two previous occasions (both during sub-freezing temps), one of the lifters had collapsed, causing a loud clacking noise. Both times, the lifter eventually filled with oil, and the engine ran ok. Here is what I did this spring: o Drove for a week with 1/2 quart ATF in place of an equal amount of oil o Drained 1 quart of oil, replaced with ATF and idled for a while at engine operating temp. I did an oil and filter change with 10W30 dino oil, no lifter problems for the months leading up to our trip. o Prior to the trip, I Replaced the valve cover gaskets. I glued the gaskets to the covers as per a suggestion on the list. I adjusted the rockers for zero backlash. I re-filled with 15W50 Mobile1 synthetic

~2-3K into our trip, in the Grand Tetons in Wyoming, after a night of camping, a lifter again collapsed. I was a bit concerned that it wouldn't correct itself, so I pulled the valve cover gasket on the driver's side where the noise was loudest to investigate. We were in a wonderful campsite with views of a lake and mountains, not a bad place to work on the van! I was careful not to drip any oil on the ground. I proceeded to adjust all the valves to 1/4 turn in, and found the rear most rocker on #4 could be pushed in with little effort, the hydraulic lifer was indeed collapsed. I adjusted the rocker until the lifter was completely compressed, essentially a solid lifter. I left a little play to account for thermal expansion while the engine was running. We made it all the way back to Vermont with no problems. In fact, our fuel economy increased considerably, and oil temps were reduced. On the way out west, we were getting 15-16mpg on the highway at ~60mph (automatic trany). After temporarily "fixing" the lifter, we got 20-22mpg in the Tetons and Yellowstone, and 18-19mpg on the highway. Previously, we had never seen fuel economy that high. Obviously the lifter had been on its way out for some time!

I haven't pulled the lifter yet to diagnose the cause of this failure, I suspect a piece of RTV from the PO may have lodged itself in the lifter. This temporary "fix" took less than 1 hour and takes relatively few tools. A 22mm (or is it 24mm?) socket and ratchet to turn the engine, a flat head screwdriver to adjust the rockers, a 10mm? socket and wrench for loosening the set nuts on the set screw on the rockers, and a longer screwdriver to remove the spring clip holding the valve covers in place. If you are willing to carry at least these few tools and either replace the valve cover gaskets or carry spares (less than $2), then you can travel in relative comfort that you will not be stranded somewhere. I expect the bad lifter in our engine needs to be replaced. Hopefully no damage was done to the rocker or other components from my adjustment on the road.

After the "adjustment" the engine also sounded much better, and what I had thought was the sound of a misfire in one of the cylinders went away.

I plan to write more about our trip when I get a chance. The only other problem was a snapped throttle cable. I fixed this with electrical crimp connectors and copper wire, not a great repair, but it got us home.

Good Luck on your trip! Ezra Hall '88 Westy, ~103K miles


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